Apparatus for fabricating an elastic nonwoven material

Abstract

An apparatus for fabricating an elastic nonwoven material generally includes a first bonding module and a second bonding module. The second bonding module is positionable in close proximity to the first bonding module. At least one of the first bonding module and the second bonding module has a face with a width dimension and a circumferential axis and is rotatable about a rotation axis. The face has a plurality of ridges. The ridges are positioned such that at least two adjacent ridges overlap along the circumferential axis.

What is claimed is: 
     
       1. An apparatus for fabricating an elastic nonwoven material, said apparatus comprising:
 a first bonding module; and 
 a second bonding module positionable in close proximity to the first bonding module, wherein at least one of the first bonding module and the second bonding module has a face with a width dimension and a circumferential axis and is rotatable about a rotation axis, the face having a plurality of ridges, each of the ridges having a plurality of interspaced lands and notches, and each of the ridges having a width and a length that is longer than the width, the ridges being spaced circumferentially about the face, wherein the ridges extend across the face by less than the width dimension, are oriented obliquely relative to the circumferential axis, and are positioned such that at least two ridges overlap along the circumferential axis such that continuous running contact is provided between the at least two ridges and one of the first and second bonding modules when rotated about the rotation axis, wherein each of the lands and each of the notches are oriented parallel to the circumferential axis and obliquely relative to the ridges. 
 
     
     
       2. The apparatus of  claim 1 , wherein the ridges are arranged in a pattern that is symmetric about an axis of symmetry oriented obliquely relative to the circumferential axis. 
     
     
       3. The apparatus of  claim 1 , wherein the ridges are discontinuous and define at least one gap along the face in the width dimension. 
     
     
       4. The apparatus of  claim 1 , wherein at least one ridge extends along a first oblique axis and at least one other ridge extends along a second oblique axis. 
     
     
       5. The apparatus of  claim 1 , wherein the ridges are arranged to overlap along the circumferential axis and in the width dimension. 
     
     
       6. The apparatus of  claim 1  further comprising at least one ridge having at least one shape of the following shapes: polygonal, rectangular, sinusoidal, and ovular. 
     
     
       7. The apparatus of  claim 1 , wherein at least one ridge is configured to define at least one of an image and an alpha-numeric character in the elastic nonwoven material. 
     
     
       8. The apparatus of  claim 1 , wherein the other of the first bonding module and the second bonding module has a contour that is continuous. 
     
     
       9. The apparatus of  claim 1 , wherein the ridges extend substantially linearly across the circumferential axis. 
     
     
       10. The apparatus of  claim 1 , wherein the ridges extend non-linearly across the circumferential axis. 
     
     
       11. A method for fabricating an elastic nonwoven material, said method comprising:
 positioning a first bonding module in close proximity to a second bonding module, wherein at least one of the first bonding module and the second bonding module includes a face with a width dimension and a circumferential axis and is rotatable about a rotation axis, the face having a plurality of ridges, each of the ridges having a plurality of interspaced lands and notches, and each of the ridges having a width and a length that is longer than the width, the ridges being spaced circumferentially about the face, wherein the ridges extend across the face by less than the width dimension, are oriented obliquely relative to the circumferential axis, and are positioned such that at least two ridges overlap along the circumferential axis such that continuous running contact is provided between the at least two ridges and one of the first and second bonding modules when rotated about the rotation axis, wherein each of the lands and each of the notches are oriented parallel to the circumferential axis and obliquely relative to the ridges; 
 rotating at least one of the first bonding module and the second bonding module; 
 directing an elastic strand between the first bonding module and the second bonding module and along a curve relative to the circumferential axis; 
 bonding the elastic nonwoven material in a first region, wherein at least a portion of the elastic strand is entrapped in the first region; and 
 bonding the elastic nonwoven material in a second region, wherein at least a portion of the elastic strand is entrapped in the second region, wherein the elastic strand extends along the curve between the first region and the second region. 
 
     
     
       12. The method of  claim 11 , wherein directing the elastic strand along the curve comprises feeding the elastic strand from a supply station in an oscillatory manner along the width dimension of the face. 
     
     
       13. The method of  claim 11 , wherein directing the elastic strand along the curve comprises directing the elastic strand between the notches defined in the ridges of the face. 
     
     
       14. An apparatus for fabricating an elastic nonwoven material including at least one elastic strand, said apparatus comprising:
 a first bonding module; 
 a second bonding module positionable in close proximity to the first bonding module, wherein at least one of the first bonding module and the second bonding module has a face with a width dimension and a circumferential axis and is rotatable about a rotation axis, the face having a plurality of first ridges oriented obliquely relative to the circumferential axis, and a plurality of second ridges oriented obliquely relative to the plurality of first ridges and to the circumferential axis, the first and second ridges being spaced circumferentially about the face, each of the first and second ridges having a plurality of interspaced lands and notches, and each of the first and second ridges having a leading edge and a trailing edge, wherein the first and second ridges are positioned such that the trailing edge of at least one first ridge overlaps with the leading edge of at least one circumferentially adjacent second ridge along the circumferential axis such that continuous running contact is provided between the ridges and one of the first and second bonding modules when rotated about the rotation axis, wherein the first bonding module and the second bonding module are positioned to receive at least one elastic strand and a nonwoven material, wherein each of the lands and each of the notches are oriented parallel to the circumferential axis and obliquely relative to the first and second ridges; and 
 a supply station configured to provide the at least one elastic strand, wherein the at least one elastic strand is directed across the width dimension along a curve relative to the circumferential axis as the at least one of the first bonding module and the second bonding module is rotated. 
 
     
     
       15. The apparatus of  claim 14 , wherein the supply station includes at least one spool containing the at least one elastic strand, wherein the supply station is configured to direct the at least one elastic strand along the curve. 
     
     
       16. The apparatus of  claim 15 , wherein the supply station is configured to oscillate the at least one elastic strand as the at least one elastic strand is unwound from the at least one spool. 
     
     
       17. The apparatus of  claim 14 , wherein the notches and lands are arranged to receive the at least one elastic strand, the notches and lands being offset to receive the at least one elastic strand along the curve. 
     
     
       18. An apparatus for fabricating an elastic nonwoven material including at least one elastic strand, said apparatus comprising:
 a first bonding module; 
 a second bonding module positionable in close proximity to the first bonding module, wherein at least one of the first bonding module and the second bonding module has a face with a width dimension and a circumferential axis and is rotatable about a rotation axis, the face having a plurality of ridges, wherein the first bonding module and the second bonding module are positioned to receive at least one elastic strand and a nonwoven material; and 
 a supply station configured to provide the at least one elastic strand, wherein the at least one elastic strand is directed across the width dimension along a curve relative to the circumferential axis as the at least one of the first bonding module and the second bonding module is rotated, wherein the ridges have notches and lands that are arranged to receive the at least one elastic strand in the notches, the notches and lands being offset to receive the at least one elastic strand along the curve, and wherein the ridges extend along a portion of the width dimension and are arranged to correspond to the curve along the circumferential axis.